Barrel Form and Manufacturing Process for Same

Abstract

A process of making an adjustable diameter barrel form includes the steps of providing a sheet formed of metal and folding the sheet along a widthwise bend. Pressure is applied to the sheet along the bend within a rolling device. The sheet is rolled within the rolling device over its length gradually moving the bend from one lengthwise end to the other lengthwise end while applying the pressure. The pressure is removed to release the sheet so that the sheet can roll up in a lengthwise direction into a coil. The rolling device can include a pair of rollers, an arbor, and a mandrel on the arbor. The rolling device can include a base plate, a press plate, and a mandrel between the plates.

Description

RELATED APPLICATION DATA[0001]This patent is related to and claims priority benefit of prior filed U.S. provisional application Ser. Nos. 61 / 331,592 filed on May 5, 2010 and 61 / 345,705 filed on May 18, 2010, each entitled “Adjustable-Diameter Barrel and Manufacturing Process.” The entire contents of these prior filed provisional applications are hereby incorporated by reference herein.BACKGROUND[0002]1. Field of the Disclosure[0003]The present invention is generally directed to spiraled or coiled metal parts and processes and methods for forming same, and more particularly to a barrel form and a process for manufacturing same.[0004]2. Description of Related Art[0005]Many implements are known to employ cylindrical barrels of a fixed-diameter that are made from a heat-conductive material such as sheet metal. In one example, hairstyling products, such as curling irons, rollers, curlers, and the like, utilize such metal barrels. Other products are also known to employ cylindrical metal ...

AI Technical Summary

Benefits of technology

[0016]In one example, the step of positioning can include positioning the sheet against two rollers that can be formed of, or that can have an outer surface formed of, an elastomeric material that can inhibit marring surfaces of the sheet but also increase friction between the outer surfaces of the two rollers and the sheet.

[0024]In one example, the step of applying pressure can include using one side of the press plate having an outer surface formed of an elastomeric material that inhibits marring surfaces of the sheet but increases friction between the outer surface of the press plate and the sheet.

Problems solved by technology

However, known techniques that can be used to form spiraled or coiled sheet metal objects are prohibitively expensive for many products and / or require time-consuming processes from start to finish.

Some products would simply become too costly to manufacture if fabricated with a coiled or spiraled sheet metal part that was produced by conventional techniques.

Thus, the roll forming machinery and tools are very expensive.

Additionally, the subsequent heat-treating, i.e., hardening, and polishing operations are also very expensive, and can be particularly difficult to perform on a rolled or coiled metal form.

Heat-treating the rolled form requires a furnace, fuel for the furnace, and significant time for the process to achieve a desired hard temper.

This secondary procedure further increases the manufacturing time and cost of the overall process to producing the roll formed barrel shape.

If attempting to use conventional rolling or roll forming techniques to fabricate a small-diameter barrel from a hardened material, i.e., negating the need for the secondary heat-treating and polishing steps, the roll forming machinery typically cannot apply sufficient force to bend or form the hardened material.

The rollers and mandrel typically cannot achieve sufficient force or loads across the distance or length required along the progression of rollers without deforming.

This is because of the high stresses or forces required to roll hardened sheet metal.

Images